Magnetic components and manufacturing method thereof

Abstract

To provide a magnetic component.SOLUTION: A magnetic component includes: a reel including a first part including an insulating material and a second part connected to the first part and including a thermoplastic material different from the insulating material; a coil including a pull-out end wrapped around the first part of the reel and secured to the second part of the reel; and an iron core penetrated by the reel.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a magnetic component and a method for manufacturing the same. [Background technology]

[0002] With the advancement of science and technology, transformers must provide high power to meet the requirements of electronic products, so the wire diameter of the coil must be increased accordingly. When the wire diameter of the coil is increased, it becomes difficult to fix the coil, and in the conventional transformer design, the coil must be fixed manually, which is inefficient and expensive. Summary of the Invention [Problem to be solved by the invention]

[0003] In view of this, an object of the present disclosure is to provide a magnetic component that can be produced automatically. [Means for solving the problem]

[0004] In order to achieve the above-mentioned objective, according to some embodiments of the present disclosure, a magnetic component includes a reel including a first portion including an insulating material and a second portion connected to the first portion and including a thermoplastic material different from the insulating material, a coil wound around the first portion of the reel and including an extension end fixed to the second portion of the reel, and an iron core inserted into the reel.

[0005] In one or more embodiments of the present disclosure, the second portion of the reel surrounds and contacts the withdrawal end of the coil.

[0006] In one or more embodiments of the present disclosure, the first portion of the reel surrounds and contacts the withdrawal end of the coil.

[0007] In one or more embodiments of the present disclosure, the first portion of the reel includes a first clamping structure and the second portion of the reel includes a second clamping structure, the second clamping structure and the first clamping structure engaging each other.

[0008] In one or more embodiments of the present disclosure, a first portion of the reel includes the extension structure and a second portion of the reel covers the extension structure.

[0009] In one or more embodiments of the present disclosure, a first portion of the reel includes an extension structure having a through hole, and a second portion of the reel includes a post that extends through the through hole and is fixedly connected to the extension structure.

[0010] According to some embodiments of the present disclosure, a method for manufacturing a magnetic component includes providing a reel including a first portion and a second portion connected to the first portion and including a thermoplastic material; winding at least one coil onto the first portion of the reel and providing an extended end of the coil on the second portion of the reel; and heating the second portion of the reel such that the second portion of the reel partially melts and covers the extended end of the coil.

[0011] In one or more embodiments of the present disclosure, the step of providing the lead-out end of the coil on the second portion of the reel includes providing the lead-out end of the coil in at least one groove in the second portion, and heating the second portion of the reel such that the at least one groove seals to cover the lead-out end of the coil.

[0012] In one or more embodiments of the present disclosure, the method for manufacturing a magnetic component further includes a step of sandwiching the lead-out end of the coil by two side walls of the groove.

[0013] In one or more embodiments of the present disclosure, the second portion of the reel includes a first groove and a second groove, and the step of heating the second portion of the reel includes contacting a heating device with the protrusion structure between the first groove and the second groove to partially melt the protrusion structure to seal the first groove and the second groove.

[0014] In one or more embodiments of the present disclosure, the protruding structure has a notch located at an end of the protruding structure, and the heating device is positioned to heat from the notch of the protruding structure.

[0015] In one or more embodiments of the present disclosure, the method for manufacturing a magnetic component further includes a step of shaping the lead end of the coil to approximate a cylindrical shape before providing the lead end of the coil in the at least one groove.

[0016] In one or more embodiments of the present disclosure, the method for manufacturing a magnetic component further includes a step of joining the first and second portions of the reel by heat fusion or engagement. Effect of the Invention

[0017] In summary, in the magnetic component of the present disclosure, the reel includes a first portion for winding the coil and a second portion for fixing the lead-out end of the coil, where the second portion includes a thermoplastic material. In manufacturing the magnetic component, the lead-out end of the coil may be positioned on the second portion of the reel (e.g., the lead-out end of the coil is fitted into a groove in the second portion), and then the second portion of the reel may be heated so that the second portion partially melts and covers the lead-out end of the coil, and the lead-out end of the coil may be fixed after the second portion has cooled. With the above arrangement, automatic production of the magnetic component may be achieved. [Brief description of the drawings]

[0018] The following description of the accompanying drawings will make the above and other objects, features, advantages and embodiments of the present disclosure more comprehensible. [Figure 1] FIG. 2 illustrates a front view of a magnetic component according to one embodiment of the present disclosure. [Diagram 2] FIG. 2 illustrates a rear view of a magnetic component according to one embodiment of the present disclosure. [Diagram 3] 2A shows a cross-sectional view of the reel of magnetic component shown in FIG. 2 taken along line 2-2'. [Figure 4] 1 shows an exploded view of the magnetic components before the coils are installed. [Diagram 5] 5 shows an exploded view of the reel shown in FIG. 4. [Figure 6] 1 shows a top view of a reel according to another embodiment of the present disclosure. [Figure 7]6 shows a cross-sectional view of the reel of magnetic components shown in FIG. 6 taken along line 6-6'. [Figure 8] 1 shows a top view of a reel according to another embodiment of the present disclosure. [Figure 9] 8A shows a cross-sectional view of the reel of magnetic components shown in FIG. 8 taken along line 8-8'. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] In order to more fully and completely describe the present disclosure, reference may be made to the accompanying drawings and the following various embodiments. The parts in the drawings are not drawn to scale and are merely for the purpose of describing the present disclosure. In the following, many practical details are described in order to fully understand the present disclosure, but it should be understood that those skilled in the art can implement the present disclosure in the absence of one or more practical details. Therefore, these details should not be used to limit the present disclosure.

[0020] Please refer to FIG. 1, which shows a front view of a magnetic component 10 according to an embodiment of the present disclosure. The magnetic component 10 includes at least one first coil 21, at least one second coil 22, a reel 30, and an iron core 50. The first coil 21 and the second coil 22 are wound around a first portion 31 of the reel 30 so as to be provided separately from each other. The first portion 31 of the reel 30 includes an insulating material such as bakelite. The iron core 50 penetrates the reel 30, specifically, covers the reel 30 and extends through an opening in the center of the reel 30 (see FIG. 4).

[0021] As shown in FIG. 1, in this embodiment, the magnetic component 10 is a transformer (in other embodiments, the magnetic component may be an inductance component), the first coil 21 is a secondary coil, and the second coil 22 is a primary coil. The first coil 21 may be multi-stranded to withstand a large current. The reel 30 further includes a plurality of conductive pins 33, which are fixedly attached to the first portion 31, and in this embodiment, the conductive pins 33 are provided on opposite sides of the first portion 31. The second coil 22 is connected to the conductive pins 33 (the drawings only show the second coil 22 connected to one conductive pin 33, but the other conductive pins 33 may be connected to the second coil 22).

[0022] Please refer to Figures 2 and 3. Figure 2 shows a rear view of the magnetic component 10 shown in Figure 1, and Figure 3 shows a cross-sectional view of the reel 30 of the magnetic component 10 shown in Figure 2 taken along line 2-2'. The reel 30 further includes a second portion 32 connected to the first portion 31, and in this embodiment, the second portion 32 is provided on one side of the first portion 31, but in other embodiments, the second portion 32 may be provided on opposite sides of the first portion 31. The second portion 32 of the reel 30 includes a thermoplastic material different from the insulating material included in the first portion 31. The first coil 21 includes a lead-out end 23 fixed to the second portion 32 of the reel 30 (i.e., a portion exposed from the conductive material at the end of the first coil 21). In some embodiments, the second portion 32 of the reel 30 covers the pull-out end 23 of the first coil 21; for example, the second portion 32 of the reel 30 may surround the pull-out end 23 and contact the outer circumferential surface of the pull-out end 23.

[0023] In the magnetic component 10 of the present disclosure, the reel 30 includes a second portion 32 for fixing the lead-out end 23 of the first coil 21, and the second portion 32 includes a thermoplastic material. When manufacturing the magnetic component 10, the lead-out end 23 of the first coil 21 may be provided on the second portion 32 of the reel 30, and then the second portion 32 of the reel 30 may be heated to partially melt and cover the lead-out end 23, and the lead-out end 23 may be fixed after the second portion 32 is cooled. Both the step of positioning the wire outlet end 23 and the step of subsequently heating the second portion 32 of the reel 30 may be performed by machine, so that the magnetic component 10 may be produced in a highly automated or fully automated manner, which not only saves labor costs but also improves production efficiency.

[0024] Meanwhile, the first portion 31 of the reel 30 is used to be wound by the first coil 21 and the second coil 22, and since there is no need to fix the first coil 21 and the second coil 22 by heat fusion, a thermosetting material may be used. According to actual requirements, the first coil 21 and the second coil 22 may be automatically wound by a machine.

[0025] See Figure 4, which shows an exploded view of the magnetic component before the coil is attached. In some embodiments, the second portion 32A of the reel 30A has one or more grooves 35 for receiving the lead-out end 23 of the first coil 21 (see Figure 2) before the lead-out end 23 of the first coil 21 is formed by heat fusing. When manufacturing the magnetic component 10, the lead-out end 23 of the first coil 21 may be placed in the groove 35 of the second portion 32A of the reel 30A, and then the second portion 32A of the reel 30A may be heated to seal the groove 35, so that the lead-out end 23 is covered and secured to the second portion 32 of the reel 30A as shown in the previous figure.

[0026] 4, in some embodiments, the predetermined width of the groove 35 is smaller than the diameter of the pull-out end 23 (see FIG. 2), and an external force must be applied to press the pull-out end 23 into the groove 35. Due to the difference in dimensions, once the pull-out end 23 is pressed into the groove 35, the two side walls of the groove 35 sandwich the pull-out end 23 of the first coil 21, so as to avoid unexpected displacement of the pull-out end 23, and thus it is easy to fix the pull-out end 23 by later heating the second portion 32A of the reel 30A.

[0027] 4 , in some embodiments, adjacent grooves 35 are separated by protruding structures 36, and a heating device (not shown) may be brought into contact with the protruding structures 36 to partially melt the protruding structures 36 and seal the grooves 35 on either side of the protruding structures 36 during manufacturing of the magnetic component 10. In some embodiments, after the protruding structures 36 are partially melted by the heating device, the heating device may further press the melted portions of the protruding structures 36 such that the molten thermoplastic material spreads laterally to seal adjacent grooves 35.

[0028] As shown in FIG. 4, in some embodiments, the protruding structure 36 has a notch 37 located at the end of the protruding structure 36. When manufacturing the magnetic component 10, a heating device may apply heat from the notch 37 of the protruding structure 36 so that the thermoplastic material next to the notch 37 melts and seals the adjacent groove 35 (e.g., the heating device may include at least one protrusion that extends into the notch 37 and abuts the inner surface of the notch 37). Meanwhile, as described above, the predetermined width of the groove 35 may be smaller than the diameter of the wire exit end 23 to pinch and fix the wire exit end 23. When the protruding structure 36 has the notch 37, the force required to press the lead end 23 into the groove 35 may be reduced.

[0029] As described above, in an embodiment in which the magnetic component 10 is a transformer, the first coil 21 is a secondary coil including multiple strands. The multiple strands typically have a large outer diameter tolerance and an irregular shape. In view of this, in some embodiments, before the lead end 23 of the first coil 21 is placed in the groove 35 of the second portion 32A, the lead end 23 may be shaped to approximate a cylindrical shape (the cross section of the lead end 23 approximates a circle) to facilitate engagement between the lead end 23 and the groove 35.

[0030] 4, in some embodiments, the core 50 includes a first magnetic member 51 and a second magnetic member 52, which are, for example, E-shaped magnetic cores, each including a flat portion 53, a shaft portion 56, and a sidewall portion 57, where the flat portion 53 of the first magnetic member 51 and the flat portion 53 of the second magnetic member 52 face the top and bottom of the first portion 31 of the reel 30A, respectively, the shaft portion 56 extends through the central opening 34 of the first portion 31, and the sidewall portion 57 faces the side surface of the first portion 31. The shaft portion 56 and the sidewall portion 57 of the first magnetic member 51 abut against the shaft portion 56 and the sidewall portion 57 of the second magnetic member 52, respectively, to form a closed magnetic circuit.

[0031] Please refer to FIG. 5, which shows an exploded view of the reel 30A shown in FIG. 4. In some embodiments, the first portion 31 and the second portion 32A of the reel 30A may be coupled by engagement. Specifically, the first portion 31 of the reel 30A includes a first clamping structure M1, and the second portion 32A includes a second clamping structure M2, and the second clamping structure M2 and the first clamping structure M1 engage with each other. The first clamping structure M1 may include one or more protrusions P, which are arranged to be inserted into a notch Q at a corresponding position of the second clamping structure M2. The first clamping structure M1 may include one or more notches Q, which are arranged to receive the protrusion P at a corresponding position of the second clamping structure M2. In some embodiments, the first portion 31 of the reel 30A includes an extension structure 38, and the first clamping structure M1 is provided on an end surface of the extension structure 38.

[0032] Please refer to Figures 6 and 7. This embodiment is different from the above-mentioned embodiment in that the first part 31B and the second part 32B of the reel 30B of this embodiment are connected by heat fusion. Specifically, in this embodiment, the second part 32B of the reel 30B is fitted onto the extension structure 38B of the first part 31B, and the edge of the second part 32B containing a thermoplastic material may be heated so that the second part 32B partially melts and covers the extension structure 38B, and the extension structure 38B may be fixed and connected after the second part 32B is cooled. In some embodiments, the extension structure 38B may have one or more slots (not shown), and when the second part 32B is heated, a part of the second part 32B may melt and flow into the slot, and when the second part 32B is cooled, the extension structure 38B may be engaged with the slot and fixed.

[0033] The second portion 32B of the reel 30B may completely cover the circumferential surface S of the extension structure 38B as shown in the drawings, but is not limited thereto. In other embodiments, the second portion 32B of the reel 30B may partially cover the circumferential surface S of the extension structure 38B such that the circumferential surface S of the extension structure 38B is partially exposed, which can similarly secure the second portion 32B.

[0034] Please refer to Figures 8 and 9. In this embodiment, the first part 31C and the second part 32C of the reel 30C are also bonded by heat fusion, but the form is different from that of the previous embodiment. Specifically, in this embodiment, the extension structure 38C of the first part 31C of the reel 30C has a first surface 61, a second surface 62 opposite to the first surface 61, and at least one through hole 65 extending from the first surface 61 to the second surface 62. The second part 32C of the reel 30C abuts the first surface 61 of the extension structure 38C and includes at least one pillar 70, the pillar 70 extends through the through hole 65, and has a head 75 at the end of the pillar 70, the width of the head 75 is greater than the width of the through hole 65, and the second part 32C can be fixed to the extension structure 38C.

[0035] The head portion 75 is formed by heating the second portion 32C including a thermoplastic material. Before forming the head portion 75 by heating, the width of the entire pillar is smaller than the width of the through hole 65, so that the pillar can pass through the through hole 65. After the pillar passes through the through hole 65, the portion of the pillar 70 extending outside the through hole 65 can be heated to melt it and form the head portion 75 having a width larger than the through hole 65.

[0036] In summary, in the magnetic component of the present disclosure, the reel includes a first portion for winding the coil and a second portion for fixing the lead-out end of the coil, where the second portion includes a thermoplastic material. In manufacturing the magnetic component, the lead-out end of the coil may be positioned on the second portion of the reel (e.g., the lead-out end of the coil is fitted into a groove in the second portion), and then the second portion of the reel may be heated so that the second portion partially melts and covers the lead-out end of the coil, and the lead-out end of the coil may be fixed after the second portion has cooled. With the above arrangement, automatic production of the magnetic component may be achieved.

[0037] Although the present disclosure has been disclosed above in the form of an embodiment, it is not intended to limit the present disclosure, and those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present disclosure. Therefore, the scope of protection of the present disclosure is based on that defined in the appended claims. [Explanation of symbols]

[0038] 10 Magnetic parts 21 First coil 22 Second coil 23 Pull-out end 30, 30A, 30B, 30C reels 31, 31B, 31C Part 1 32, 32A, 32B, 32C 2nd part 33 Conductive pin 34 Aperture 35 Groove 36 Protrusion structure 37 Notch 38, 38B, 38C extension structure 50 Iron Core 51 First magnetic member 52 Second magnetic member 53 Plane part 56 Shaft 57 Side wall 61 1st surface 62 2nd surface 65 Through hole 70 Column 75 Head M1 First fastening structure M2 2nd tightening structure P convex part Q Notch S circumferential surface

Claims

1. a reel including a first portion including an insulating material and a second portion connected to the first portion, the second portion including a thermoplastic material different from the insulating material; a coil wound around the first portion of the reel and including an extension end secured to the second portion of the reel; An iron core that is inserted into the reel; Including, the first portion of the reel includes a first clamping structure and the second portion of the reel includes a second clamping structure, the second clamping structure and the first clamping structure engaging each other; The second portion of the reel is heated such that the second portion of the reel partially melts and coats the lead-out end of the coil. Magnetic parts.

2. 2. The magnetic component of claim 1, wherein the second portion of the reel surrounds and contacts the lead-out end of the coil.

3. 2. The magnetic component of claim 1, wherein the insulating material of the first portion of the reel is a thermosetting material.

4. providing a reel including a first portion and a second portion connected to the first portion and including a thermoplastic material, the first portion of the reel including a first clamping structure and the second portion of the reel including a second clamping structure, the second clamping structure and the first clamping structure engaging each other; winding at least one coil onto the first portion of the reel and providing an exit end of the coil on the second portion of the reel; heating the second portion of the reel such that the second portion of the reel partially melts and coats the lead-out end of the coil; A method for manufacturing a magnetic component comprising the steps of:

5. the step of providing the lead-out end of the coil on the second portion of the reel includes providing the lead-out end of the coil in at least one groove in the second portion; 5. The method for manufacturing a magnetic component according to claim 4, wherein the step of heating the second portion of the reel includes heating the second portion of the reel such that the at least one groove is sealed to cover the lead-out end of the coil.

6. The method for manufacturing a magnetic component according to claim 5 , further comprising the step of sandwiching the lead-out end of the coil between two side walls of the groove.

7. 6. The method for manufacturing a magnetic component according to claim 5, wherein the at least one groove includes a first groove and a second groove, and the step of heating the second portion of the reel includes contacting a heating device with the protruding structure between the first groove and the second groove so as to partially melt the protruding structure to seal the first groove and the second groove.

8. The method for manufacturing a magnetic component according to claim 7, wherein the protruding structure has a notch located at an end of the protruding structure, and the heating device is disposed to heat the protruding structure from the notch.

9. The method for manufacturing a magnetic component according to claim 5, further comprising the step of shaping the lead end of the coil to approximate a cylindrical shape before providing the lead end of the coil in the at least one groove.

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